EP0843763B2 - Floor covering, consisting of hard floor panels and method for manufacturing such floor panels - Google Patents

Floor covering, consisting of hard floor panels and method for manufacturing such floor panels Download PDF

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Publication number
EP0843763B2
EP0843763B2 EP97928169A EP97928169A EP0843763B2 EP 0843763 B2 EP0843763 B2 EP 0843763B2 EP 97928169 A EP97928169 A EP 97928169A EP 97928169 A EP97928169 A EP 97928169A EP 0843763 B2 EP0843763 B2 EP 0843763B2
Authority
EP
European Patent Office
Prior art keywords
floor
panels
covering according
floor panels
floor covering
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP97928169A
Other languages
German (de)
French (fr)
Other versions
EP0843763B1 (en
EP0843763A1 (en
Inventor
Stefan Simon Gustaaf Moriau
Mark Gaston Maurits Cappelle
Bernard Paul Joseph Thiers
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unilin Beheer BV
Original Assignee
Unilin Beheer BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=25663046&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=EP0843763(B2) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority claimed from BE9600527A external-priority patent/BE1010339A3/en
Priority to EP10010811A priority Critical patent/EP2275622A3/en
Priority to EP05077327A priority patent/EP1614829B1/en
Priority to EP09010320A priority patent/EP2116668A1/en
Priority to EP05076551A priority patent/EP1589161B1/en
Priority to EP05077262A priority patent/EP1612346B1/en
Priority to EP10010508A priority patent/EP2280133A3/en
Priority to EP00201514A priority patent/EP1026341B1/en
Priority to EP05077348.0A priority patent/EP1614828B1/en
Priority to EP08020631.1A priority patent/EP2077358B1/en
Priority to EP10011062A priority patent/EP2275623A3/en
Priority to EP10010484A priority patent/EP2280132A3/en
Priority to EP08021267A priority patent/EP2031147A3/en
Priority to EP05075560A priority patent/EP1541778B1/en
Priority to EP10010510A priority patent/EP2280135A3/en
Application filed by Unilin Beheer BV filed Critical Unilin Beheer BV
Priority to EP08020830.9A priority patent/EP2031148B1/en
Priority to EP03076384A priority patent/EP1338721B1/en
Priority to EP10010483A priority patent/EP2280131A3/en
Priority to EP00201515A priority patent/EP1024234B2/en
Priority to EP02076363A priority patent/EP1223267B2/en
Priority to EP10010509A priority patent/EP2280134A3/en
Priority to EP05075635A priority patent/EP1541779B1/en
Priority to EP07024053.6A priority patent/EP1898026B1/en
Priority to EP08075888A priority patent/EP2031149B1/en
Publication of EP0843763A1 publication Critical patent/EP0843763A1/en
Publication of EP0843763B1 publication Critical patent/EP0843763B1/en
Publication of EP0843763B2 publication Critical patent/EP0843763B2/en
Application granted granted Critical
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/02038Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27CPLANING, DRILLING, MILLING, TURNING OR UNIVERSAL MACHINES FOR WOOD OR SIMILAR MATERIAL
    • B27C5/00Machines designed for producing special profiles or shaped work, e.g. by rotary cutters; Equipment therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27DWORKING VENEER OR PLYWOOD
    • B27D5/00Other working of veneer or plywood specially adapted to veneer or plywood
    • B27D5/006Trimming, chamfering or bevelling edgings, e.g. lists
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27FDOVETAILED WORK; TENONS; SLOTTING MACHINES FOR WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES
    • B27F1/00Dovetailed work; Tenons; Making tongues or grooves; Groove- and- tongue jointed work; Finger- joints
    • B27F1/02Making tongues or grooves, of indefinite length
    • B27F1/06Making tongues or grooves, of indefinite length simultaneously along opposite edges of a board
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27MWORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M3/00Manufacture or reconditioning of specific semi-finished or finished articles
    • B27M3/04Manufacture or reconditioning of specific semi-finished or finished articles of flooring elements, e.g. parqueting blocks
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/02005Construction of joints, e.g. dividing strips
    • E04F15/02011Construction of joints, e.g. dividing strips with joint fillings integrated in the flooring elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/02005Construction of joints, e.g. dividing strips
    • E04F15/02016Construction of joints, e.g. dividing strips with sealing elements between flooring elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/04Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/10Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16BDEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/0004Joining sheets, plates or panels in abutting relationship
    • F16B5/0008Joining sheets, plates or panels in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edge
    • F16B5/0012Joining sheets, plates or panels in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edge a tongue on the edge of one sheet, plate or panel co-operating with a groove in the edge of another sheet, plate or panel
    • F16B5/0016Joining sheets, plates or panels in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edge a tongue on the edge of one sheet, plate or panel co-operating with a groove in the edge of another sheet, plate or panel with snap action
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16BDEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/0004Joining sheets, plates or panels in abutting relationship
    • F16B5/008Joining sheets, plates or panels in abutting relationship by a rotating or sliding and rotating movement
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/02005Construction of joints, e.g. dividing strips
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/02005Construction of joints, e.g. dividing strips
    • E04F15/02033Joints with beveled or recessed upper edges
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00Joining sheets or plates or panels
    • E04F2201/01Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0107Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00Joining sheets or plates or panels
    • E04F2201/01Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0107Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges
    • E04F2201/0115Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges with snap action of the edge connectors
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00Joining sheets or plates or panels
    • E04F2201/01Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0138Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels perpendicular to the main plane
    • E04F2201/0146Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels perpendicular to the main plane with snap action of the edge connectors
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00Joining sheets or plates or panels
    • E04F2201/01Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0153Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00Joining sheets or plates or panels
    • E04F2201/01Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0153Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
    • E04F2201/0161Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement with snap action of the edge connectors
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00Joining sheets or plates or panels
    • E04F2201/02Non-undercut connections, e.g. tongue and groove connections
    • E04F2201/023Non-undercut connections, e.g. tongue and groove connections with a continuous tongue or groove
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00Joining sheets or plates or panels
    • E04F2201/02Non-undercut connections, e.g. tongue and groove connections
    • E04F2201/026Non-undercut connections, e.g. tongue and groove connections with rabbets, e.g. being stepped
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/16Two dimensionally sectional layer
    • Y10T428/163Next to unitary web or sheet of equal or greater extent
    • Y10T428/164Continuous two dimensionally sectional layer
    • Y10T428/167Cellulosic sections [e.g., parquet floor, etc.]

Definitions

  • This invention relates to a floor covering, consisting of hard floor panels, as well as to a method for manufacturing such floor panels.
  • the invention is intended for so-catted laminated floors, but generally it can also be applied for other kinds of floor covering, consisting of hard floor panels, su ch as veneer parquet, prefabricated parquet, or other floor panels which can be compared to laminated floor.
  • the floor panels are attached at the underlying floor, either by glueing or by nailing them on.
  • This technique has as a disadvantage that it is rather complicated and that subsequent changes can only be made by breaking out the floor panels.
  • the floor panels are installed loosely onto the underground, whereby the floor panels mutually match into each other by means of a tongue and groove coupling, whereby mostly they are glued together in the tongue and groove, too
  • the floor obtained in this manner also called a floating parquet flooring, has as an advantage that it is easy to install and that the complete floor surface can move which often is convenient in order to receive possible expansion and shrinkage phenomena.
  • connection elements made of metal are provided between the single floor panels in order to keep them together.
  • Such connection elements are rather expensive in manufacturing them and, furthermore, their provision or the installation thereof is a time-consuming occupation.
  • US-A-4 426 820 discloses components for assembling a sports ground (surface) preferably from plastics material.
  • a floor covering consists of hard floor panels comprising a core, the panels being intended to be laid to provide an upwardly facing, flat surface lying in a first horizontal plane and a downwardly facing, substantially flat surface lying in a second horizontal plane.
  • the panels are provided, at least at the edges of two opposite sides, with coupling parts formed in one piece with the core and cooperating with each other substantially in the form of a tongue and a groove.
  • the groove is at least partially delimited by an upper lip and a lower lip, whereby the lower lip extends beyond the upper lip.
  • the coupling parts are provided with integrated mechanical locking means which prevent the drifting apart of two coupled panels in a direction perpendicular to the related edge and parallel to the underside of the coupled floor panels.
  • the coupling means of US-A-4 426 820 are however not apt for use in thin hard flooring panels such as wood-based laminated flooring panels.
  • the invention aims at an improved floor covering of the aforementioned type, the floor panels of which can be coupled to each other in an optimum manner and/or the floor panels of which can be manufactured in a smooth manner, and whereby preferably one or more of the aforementioned disadvantages are excluded.
  • the invention also aims at a floor covering which shows the advantage that no mistakes during installing, such as gaps and such, can be created:
  • the invention also aims at a floor covering whereby the subsequent development of gaps is excluded or at least counteracted in an optimum manner, whereby also the possibility of the penetration of dirt and humidity is minimalized.
  • the invention relates to a floor covering as defined in claim 1.
  • the coupling parts may be provided with locking means which, in the engaged position of two or more of such floor panels, exert a tension force upon each other which forces the floor panels towards each other.
  • the coupling parts provide for an interlocking free from play, as well as due to the fact that these coupling parts are manufactured in one piece, from the basic material of the floor panels, a perfect connection between adjacent floor panels can always be guaranteed, even with repeated expansion and shrinkage of the floor surface.
  • the floor panels consist of elongated panels and the coupling parts described above are applied at two opposite sides of these panels.
  • coupling parts are provided at the other two sides, too, either of another construction than described above or not.
  • the core use shall be made of finely-ground wood which is glued, more particularly, watertight glued. Still more particularly, for the core use shall be made of so-called HDF board (High Density Fibreboard) or MDF board (Medium Density Fibreboard).
  • HDF board High Density Fibreboard
  • MDF board Medium Density Fibreboard
  • the surfaces obtained with HDF and MDF also have the advantage that the floor panels mutually can fluently be shifted alongside each other in interlocked condition, even when engaged with a tensioning force.
  • the inventor also found out that the aforementioned materials, in particular HDF and MDF, show ideal features in order to realize a connection, such as mentioned above, as these materials show the right features in respect to elastic deformation in order to, on one hand, realize a snap-together effect, and, on the other hand, receive expansion and shrinkage forces in an elastic manner, whereby it is avoided that the floor panels come unlocked or are damaged in an irreparable manner.
  • the floor covering preferably is form ed by joining the floor panels into each other free of glue.
  • the connections are of such nature that the floor panels canbe disassembled without being damaged, such that, for example, when moving, they can be taken along in order to be placed again. It is, however, clear that a glueing between tongue and groove is not excluded.
  • the invention also relates to a method for the manufacturing of the aforementioned floor panels which shows the advantage that the tongues and/or grooves, including the corresponding locking means, can be provided at the floor panels at high production speeds without problems. More particularly, it aims at a method which allows that the rather complicated forms of the tongue and the groove of the aforementioned floor panels can be realized completely by means of milling cutters, the diameter of which can be chosen independently of the form to be realized, such that the use of small milling cutters, for example finger cutters, with diameters smaller than the depth of the tongue or groove can be excluded.
  • this method shows the characteristic that the tongue and/or groove is realized by means of a milling process with at least two subsequent milling cycles by means of milling cutters which are positioned in different angles in respect to the related floor panel.
  • milling cutters which are positioned in different angles in respect to the related floor panel.
  • milling cutters are used which extend outside the groove, respectively the tongue. More particularly the diameters of these milling cutters shall at least be 5 times and even better 20 times larger than the thickness of the floor panels.
  • milling cutters showing the aforementioned diameters has as an advantage that the normal production speeds can be maintained which are also applied during milling of a classical straight tongue and groove. There is also the advantage obtained that the installation of such milling cutters induce only minor or no additional costs because such milling cutters can be placed directly upon a motor shaft and/or the usual machines can be used.
  • the invention relates to a floor covering which is composed of hard floor panels 1, for example, such as shown in figure 1.
  • These floor panels 1 can be of various shape, for example, rectangular or square, or of any other shape.
  • they shall be manufactured in an elongated form, such as shown in figure 1, for example, with a length of 1 to 2 meters.
  • the thickness can also vary, but is preferably 0,5 to 1,5 cm, and more particularly 0.8 cm.
  • Each floor panel 1 is at least at the edges of two opposite sides provided with coupling parts which allow that two adjacent floor panels 1 can be coupled to each other.
  • the coupling parts at each pair of opposite edges may be of the same or of different kind
  • the coupling parts 4-5 are provided with integrated mechanical locking parts 6 which prevent the drifting apart of two coupled floor panels 1 into a direction D perpendicular to the respective sides 2-3 and parallel to the underside 7 of the coupled floor panels 1; the coupling parts 4-5 and the locking means 6 are realized in one piece with the core 8 of the floor panels 1: the coupling parts 4-5 have such a shape that two subsequent floor panels 1 can be engaged into each other exclusively by turning, and the coupling parts 4-5 preferably provide in an intertocking free from play according to all directions in the plane which is situated perpendicular to the aforementioned edges.
  • the coupling parts 4-5 can be realized in various forms, although the basic forms thereof will always be formed by a tongue 9 and a groove 10.
  • the related floor panel 1 is provided with coupling parts 4-5 and locking means 6 which allow to mutually engage two floor panels 1 by means of a turning movement, without the occurance of any snap-together effect.
  • the locking means 6 consist of a first locking element 11 , formed by a protrusion with a bent round shape at the lower side 12 of the tongue 9, and a second locking element 13, formed by a recess with a bent hollow shape in the lower wall 14 of the groove 10.
  • the locking elements 11-13 provide for that two floor panels 1 which are coupled to each other can not perform a lateral movement in the horizontal plane in respect to each other.
  • the curvatures preferably are circle-shaped.
  • the bottom side 12 has a curvature with a radius R1, the center of which coincides with the related upper edge 15 of the floor panel 1, whereas the lower wall 14 shows a curvature with a radius R2 which is equal to the radius R1. but whereby its center coincides with the related upper edge 16.
  • Radii R1 and R2 may also be applied which are larger or smaller than the distance to the upper edge 15, 16 respectively, and/or which differ from each other in size.
  • the upper side 17 of the tongue 9 and the upper wall 18 of the groove 10 are preferably flat and preferably are situated in the horizontal plane.
  • the front sides 19 and 20 of the tongue 9 and the groove 10 of two interlocked floor panels 1 preferably do not fit closely against each other, such, that in between an intermediate space 21 is created into which possible dust remainders or such can be pushed away by means of the tongue 9.
  • the tongue 9 and the groove 10 preferably have shapes which are complementary to each other, such that the tongue 9 in the engaged condition of two floor panels 1 precisely sits against the upper wall 18 and the lower wall 14 of the groove 10, whereby a pressure P. executed onto the upper lip 22, is received not only by this lip 22, but by the complete structure, because this pressure can be transmitted through the tongue 9 and the lower lip 23.
  • a chamfer 24 and a recess 25 can be provided, as represented in figures 2 to 4, as a result of which is obtained that the subsequent floor panels 1 can easily be pushed into each other, such that no possible ridges or such render the good insertion difficult.
  • the floor panels 1 according to the invention can also, along the sides 26-27 which are at a right angle to the sides 2-3. be provided with coupling parts 28-29 which have locking means 30, too.
  • the coupling parts 28-29 are also realized in the shape of a tongue 31 and a groove 32.
  • the locking means 30 do not have to be of the same nature as the locking means 6.
  • locking means are applied which allow for an engagement and inter-locking by means of a translation movement T only, as represented in figures 6 and 7.
  • the locking means 30 consist of a snap-together connection with locking elements 33 and 34 which grip behind each other.
  • the locking element 33 consists of a protrusion of the lower side 35 of the tongue 31 which can take place in a recess 36 in the lower wall 37 of the groove 32.
  • the locking element 34 is formed by the upward directed part which limits the recess 36.
  • the locking elements 33-34 have contact planes 38-39 which are parallel to each other and extend in an inclined manner, according to a direction which simplifies the snapping-together.
  • the tangent line L which is determined by the contact planes 38-39, hereby forms an angle A with the underside 7 which is smaller than 90°.
  • the locking elements 33-34 preferably are provided with inclined portions 40 and 41 which, when engaging two floor panels 1, cooperate with each other in such a manner that the locking elements 33-34 can easily be pushed over each other until they grip behind each other by means of a snap-together effect.
  • the thickness W1 of the tongue 31 preferably is equal to the width W of the groove 32, such that the upper lip 42, when exerting a pressure P, is supported by the tongue 31 which, in its turn, then is supported by the lower lip 43.
  • a recess 44 and a chamfer 45 are provided also at the edges 28-29.
  • the lower lip 43 as represented in figures 5 to 7, is longer than the upper lip 42.
  • the locking elements 46-47 are also provided at the lower side 12 of the tongue 9 and the lower wall 14 of the groove 10.
  • the locking elements 46-47 have contact surfaces 48-49 which are at an angle with the plane of the floor panel 1.
  • a coupling is obtained which is interlocked in a particularly fixed manner.
  • the locking elements 46-47 possibly can be realized in such a manner that substantially only a linear contact is obtained, for example, because the contact surfaces directed towards each other are realized with different curvatures.
  • the surfaces, directed towards each other, of the locking elements 46-47 hereby consist of bent surfaces.
  • the tangent line L forms an angle A which is smaller than 90°, and even better is smaller than 70°.
  • the locking element 46 preferably has two portions with a different curvature, on one hand, a portion 50 with a strong curvature and, on the other hand, a portion 51 with a weak curvature.
  • the portion 50 with the strong curvature provides for the formation of a firm coupling.
  • the portion 51 with the weak curvature allows that the coupling parts 4-5 can be brought into each other easily.
  • the intermediate space S forms a chamber which offers space for dust and similar which, when engaging two floor panels 1, gets there eventually.
  • a connection such as represented in figures 7 to 9
  • the tongue 9-31 has a shape, thickening towards below, which can cooperate with a widened portion in the groove 10.
  • a variant is represented whereby at least at the height of the upper edges 15-16, a sealing material 52 is provided, as a result of which a watertight sealing can be guaranteed.
  • This sealing material 52 may consist of a strip or covering which is provided previously at the floor panel 1, either at one or both upper edges 15-16.
  • FIG 11 a further variant is represented, whereby the locking means 6 are formed by an upward directed portion 53 at the tongue 9 which, as a result of a turning movement, is brought behind a downward-directed portion 54 at the upper wall 18. More particularly, this is obtained by realizing the upper side 17 and the upper wall 18 with a curvature R3, the center of which is situated at the edges 15-16, and realizing the lower side 12 and the lower wall 14 with a radius R4, the center of which is also situated at the upper edges 15 and 16, respectively.
  • radii R3-R4 can be chosen otherwise, too.
  • the difference between, on one hand, the radius R1, R3 respectively, and, on the other hand, the radius R2, R4 respectively, preferably should not be larger than 2 mm.
  • the center of these radii is situated inside the circle C1, C2 respectively, which extends with a radius R5 of 3 mm around the upper edge 15, 16 respectively, such as, for example, indicated In figure 2.
  • the lower lip 23-43 is realized longer than the upper lip 22-42.
  • the difference E between the upper lip 22-42 and the lower lip 23-43, measured in the plane of the floor panel and perpendicular to the longitudinal direction of the groove 10, is kept smaller than one time the total thickness F of the floor panel 1.
  • this total thickness F shall never be less than 5 mm.
  • the small dimension of the difference E offers the advantage that the lower lip must not be strengthened by a reinforcement strip or the like.
  • the central line M1 through the tongue 9 and the groove 10 is situated lower than the center M2 of the floor panel 1, such, that the upper lip 22-42 is thicker than the lower lip 23-43.
  • this is essential in this kind of connections, because then it is the lower lip 23-43 which bends, such that the upper side of the floor panel 1 is kept free of possible deformations.
  • the invention shows its usefulness, in first instance, preferably with laminated flooring, due to the reasons explained in the introduction.
  • such laminated flooring preferably consists of a core 8 made of MDF board, HDF board or similar, whereby at least at the upper side of this core 8 one or more layers of material are provided.
  • the laminated flooring is provided with a decorative layer 55 and a protective top layer 56.
  • the decorative layer 55 is a layer, impregnated with resin, for example, made of paper, which can be imprinted with a variety of patterns, such as a wood pattern, a pattern in the form of stone, cork, or similar or even with a fancy pattern.
  • the protective top layer 56 preferably also consists of a layer saturated with resin, for example, melamine resin, made of a transparent material.
  • a backing layer 58 shaft be applied at the underside 7. forming a counterbalancing element for the top layers and, thus, guaranteeing the stability of the form of the floor panel 1.
  • This backing layer 58 may consist of a material, for example paper, impregnated with a resin, for example, a melamine resin.
  • the tongue 9 and the groove 10, and preferably also the tongue 31 and the groove 32 are applied by means of a milling process.
  • the floor panels 1 preferably shall be displaced by means of two perpendicular movements V1 and V2, whereby during the first movement profiles at two opposite edges are provided, in this case the longitudinal edges, by means of milling devices 59-60, whereas during the second movement profiles are provided at the other edges, in this case the small edges, by means of milling devices 61-62.
  • the floor panels 1 preferably are put with their decorative layer directed downward.
  • each respective tongue 9-31 and groove 10-32 are realized by means of a milling process with at least two subsequent milling cycles by means of milling cutters which are positioned at different angles in reference to the related floor panel 1.
  • FIG. 13 This is illustrated in figures 13, 14 and 15, wherein it is represented how a groove 10 is realized by means of two milling cycles by means of two milling cutters 63 and 64.
  • Figures 16 and 17 represent how the tongue 9 is realized by means of milling cutters 65 and 66.
  • the figures 18-19 and 20-21 represent similar views showing how the groove 32 and the tongue 31 are realized by means of milling cutters 67-68 and 69-70, positioned at an angle.
  • each time substantially the final shape of one flank is realized.
  • the milling cutter 63 of figure 14 determines the final shape of the lower flank 71 of the groove 10
  • the milling cutter 64 determines the final shape of the upper flank 72.
  • mining cutters 63 to 72 shall be applied, having diameters G which are at least 5 times, and even better at least 20 times larger than the thickness F of the floor panels 1.
  • milling cutters Apart of the mentioned milling cutters, preferably still other milling cutters are applied, for example, in order to remove a part of the material to be removed already during a first premachining cycle.
  • an important characteristic herein consists in that the coupling parts 4-5 are provided with locking means 6 which, in engaged condition, exert a tension force upon each other, as a result of which the engaged floor portions 1 are forced towards each other.
  • this is realized preferably by providing the coupling parts with an elastically bendable portion, in this case the lip 43, which, in engaged condition, is at least partially bent and in this way creates a tension force which provides for that the engaged floor panels 1 are forced towards each other.
  • the hereby resulting bending V. as well as the tension force K resulting herefrom, are indicated in the enlargement of figure 23.
  • the bendable portion in this case the lip 43, preferably is provided, as represented, with an inwardly inclined contact surface 73 which preferably can cooperate with a corresponding contact surface 74.
  • These contact surfaces 73-74 are similar to the aforementioned contact surfaces 39-38 and also similar to the inclined portions of the lower lip of figures 5 to 7.
  • the angle A of the contact surfaces 73-74 in respect to the horizontal plane is situated between 30 and 70 degrees.
  • an angle A of 30 to 70 degrees is ideal in order, on one hand, to effect an optimum pressing-together of the floor panels 1 and, on the other hand, to obtain that the floor panels 1 can easily be engaged, respectively disassembled.
  • the pressing force K1 preferably is delivered by the aforementioned lip 43, the invention does not exclude other forms of embodiment whereby this force is delivered by other bendable portions.
  • the bending V is relatively small, for example, several hundredths up to several tenths of a millimeter, and does not have an influence upon the placement of the floor covering. Furthermore is noted that such floor covering generally is placed upon an underlayer which is elastically compressible, as a result of which the bending V of the lip 43 exclusively results in the fact that the underlayer locally is compressed somewhat more.
  • the lip 43 is bent apart and that it remains somewhat bent apart in engaged position, also the advantage is effected that, when exerting a pressure upon the floor covering, for example, when placing an object thereupon, the pressing-togetherforce is enhanced and, thus, the development of gaps is counteracted even more.
  • HDF and MDF also offer the advantage that smooth surfaces are obtained, as a result of which the locking elements can be moved easily over each other.
  • a further particular characteristic of the embodiment of figures 22 to 25 consists in that the floor panels 1 can be engaged by means of a turning movement, as represented in figure 24, as well as by means of shifting them towards each other, as represented in figure 25, preferably in such a manner that, during the engagement by means of the turning movement, a maximum bending Vm results in the coupling parts, more particularly in the lip 43, which bending Vm is less pronounced, if not non-existent, as in the figures 2 to 4, in comparison to the bending Vm which results when the floor panels 1 are engaged by means of shifting them towards each other.
  • the advantage of this consists in that the floor panels 1 can be engaged easily by means of a turning movement, in otherwords by means of the angling down or pivoting thereof, without necessitating a tool therefore, whereas it still remains possible to engage the floor panels also by means of shifting them.
  • This latter is useful, in first instance, when the last panel has to be placed partially under a door frame or similar. In this case, the floor panel 1 can be pushed under the door frame with the side which does not have to be engaged and subsequently, possibly by means of tools, can be snapped into the adjacent floor panel 1.
  • the four sides 2-3-26-27 are provided with coupling parts 4-5-28-29
  • these coupling parts can be realized in such a manner that in one direction a firmer engagement than in the other direction is effected.
  • the locking at the small sides 26-27 preferably shall be more pronounced than at the longitudinal sides 2-3.
  • the length of the coupling at the small sides, namely, is smaller and, in principle, less firm. This is compensated by providing in a more pronounced locking.
  • This difference in engagement can be obtained by realizing the contact surfaces 73-74 under different angles.
  • the aforementioned protrusion is bordered by at least two portions 75-76, respectively a portion 75 with a strong inclination which provides for the locking, and a portion 76 with a weaker inclination which renders the engagement of the coupling parts easier.
  • these portions 75-76 are formed by straight planes, but, as already described in reference to figure 9, use can also be made of curved portions 50-51. In figure 5, these are the contact surface 38 and the inclined portion 40.
  • the floor panels 1 comprise coupling parts 4-5 and/or 28-29 showing one of the following or the combination of two or more of the following features:
  • an important characteristic of the embodiment of the invention consists in that the locking means 6, in otherwords, the portion providing for the snap-together and engagement effect, are situated in that portion of the lower lip 23-43 which extends beyond the upper lip 22-42, more particularly, that the lowermost point 87 of the locking part 33 is situated under the top layer of the floor panel 1.
  • this top layer is indicated in the figures 22 to 25 only as a single layer.
  • the combination of features, that the lower lip 23-43 extends further than the upper lip 22-42, that the locking means 6 are formed at least by means of a portion which inwardly slopes downward, and that this portion, at least partially, is located in the portion of the lower lip 23-43 which extends beyond the upper lip 22-42, is particularly advantageous, among others, in comparison with the coup tings for floor panels described in the documents WO 94/01 628. WO 94/26999. WO 96/27719 and WO 96/27721.
  • the sloping portion offers the advantage that the floor panels 1 can be disassembled again.
  • the fact that this sloping portion is situated in the further extending portion of the lower lip 23-43 additionally to this offers the advantage that no deformations can occur during coupling which manifest themselves up to the top layer.
  • the aforementioned portion i.e. the contact surface 39 or 73, preferably extends in such a manner that the distance up to the upper edge 16 diminishes from below in upward direction, in other words, such that, as represented in figure 22, the distance X2 is smaller than the distance X1. This is also the case in figure 7.
  • this portion only starts at a clear distance E1 from the upper lip 42.
  • the floor panels 1 are treated at their sides 2-3 and/or 26-27 with a surface densifying agent, more particularly a surface hardening agent, which preferably is chosen from the following series of products: impregnation agents, pore-seating agents, lacquers, resins, oils, paraffines and similar.
  • a surface densifying agent more particularly a surface hardening agent, which preferably is chosen from the following series of products: impregnation agents, pore-seating agents, lacquers, resins, oils, paraffines and similar.
  • impregnation 88 is represented schematically. This treatment can be performed over the complete surface of the sides 2-3 and/or 26-27 or only over well-defined portions hereof, for example, exclusively the surfaces of the tongue 9 and the groove 10.
  • the treatment with a surface densifying agent offers, in combination with the snap-together effect, the advantage that in various aspects better coupling features are obtained.
  • the coupling parts 4-5 and/or 28-29 better keep their shape and strength, even it the floor panels 1 are engaged and disassembled repeatedly. Since for the core 8 use is made of HDF, MDF or similiar, by means of this treatment such a better quality of surface condition is obtained, that no abrasion of material occurs during engaging, respectively during disassembling.
  • This treatment also offers the advantage that, at least in the case of a surface hardening, the aforementioned elastic tensioning effect is enhanced.

Abstract

Floor covering, consisting of hard floor panels (1) which, at least at the edges of two opposite sides (2-3, 26-27), are provided with coupling parts (4-5, 28-29), cooperating with each other, substantially in the form of a tongue (9-31) and a groove (10-32), characterized in that the coupling parts (4-5, 28-29) are provided with integrated mechanical locking means (6) which prevent the drifting apart of two coupled floor panels into a direction (R) perpendicular to the related edges (2-3, 26-27) and parallel to the underside (7) of the coupled floor panels (1).

Description

  • This invention relates to a floor covering, consisting of hard floor panels, as well as to a method for manufacturing such floor panels.
  • In first instance, the invention is intended for so-catted laminated floors, but generally it can also be applied for other kinds of floor covering, consisting of hard floor panels, su ch as veneer parquet, prefabricated parquet, or other floor panels which can be compared to laminated floor.
  • It is known that such floor panels can be applied in various ways.
  • According to a first possibility, the floor panels are attached at the underlying floor, either by glueing or by nailing them on. This technique has as a disadvantage that it is rather complicated and that subsequent changes can only be made by breaking out the floor panels.
  • According to a second possibility, the floor panels are installed loosely onto the underground, whereby the floor panels mutually match into each other by means of a tongue and groove coupling, whereby mostly they are glued together in the tongue and groove, too The floor obtained in this manner, also called a floating parquet flooring, has as an advantage that it is easy to install and that the complete floor surface can move which often is convenient in order to receive possible expansion and shrinkage phenomena.
  • A disadvantage with a floor covering of the above-mentioned type, above all, if the floor panels are installed loosely onto the underground, consists in that during the expansion of the floor and its subsequent shrinkage, the floor panels themselves can drift apart, as a result of which undesired joints can be formed, for example, if the glue connection breaks.
  • In order to remedy this disadvantage, techniques have already been thought of whereby connection elements made of metal are provided between the single floor panels in order to keep them together. Such connection elements, however, are rather expensive in manufacturing them and, furthermore, their provision or the installation thereof is a time-consuming occupation.
  • Examples of embodiments which apply such metal connection elements are described, among others, in the documents WO 94/26999 and WO 93/13280.
  • Furthermore, couplings are known which allow to snap floor parts into each other, a.o. from the documents WO 94/1628. WO 96/27719 and WO 96/27721. The snapping-together effect obtained with these forms of embodiment, however, does not guarantee a 100-percent optimum counteraction against the development of gaps between the floor panels, more particularly, because in fact well-defined plays have to be provided in order to be sure that the snapping-together is possible.
  • From GB 424.057, a coupling for parquetry parts is known which, in consideration of the nature of the coupling, only is appropriate for massive wooden parquetry.
  • Furthermore, there are also couplings for panels known from the documents GB 2.117.813, GB 2.256.023 and DE 3.544.845. These couplings, however, are not appropriate for connecting floor panels.
  • US-A-4 426 820 discloses components for assembling a sports ground (surface) preferably from plastics material. Such a floor covering consists of hard floor panels comprising a core, the panels being intended to be laid to provide an upwardly facing, flat surface lying in a first horizontal plane and a downwardly facing, substantially flat surface lying in a second horizontal plane. The panels are provided, at least at the edges of two opposite sides, with coupling parts formed in one piece with the core and cooperating with each other substantially in the form of a tongue and a groove. The groove is at least partially delimited by an upper lip and a lower lip, whereby the lower lip extends beyond the upper lip. The coupling parts are provided with integrated mechanical locking means which prevent the drifting apart of two coupled panels in a direction perpendicular to the related edge and parallel to the underside of the coupled floor panels. The coupling means of US-A-4 426 820 are however not apt for use in thin hard flooring panels such as wood-based laminated flooring panels.
  • The invention aims at an improved floor covering of the aforementioned type, the floor panels of which can be coupled to each other in an optimum manner and/or the floor panels of which can be manufactured in a smooth manner, and whereby preferably one or more of the aforementioned disadvantages are excluded.
  • The invention also aims at a floor covering which shows the advantage that no mistakes during installing, such as gaps and such, can be created:
  • Furthermore, the invention also aims at a floor covering whereby the subsequent development of gaps is excluded or at least counteracted in an optimum manner, whereby also the possibility of the penetration of dirt and humidity is minimalized.
  • To this aim the invention relates to a floor covering as defined in claim 1.
  • The coupling parts may be provided with locking means which, in the engaged position of two or more of such floor panels, exert a tension force upon each other which forces the floor panels towards each other. As a result of this is effected that not only during installing the formation of gaps is counteracted, but also in a later stage the development of gaps, as a result of which causes whatsoever, is counteracted.
  • Due to the fact that the coupling parts provide for an interlocking free from play, as well as due to the fact that these coupling parts are manufactured in one piece, from the basic material of the floor panels, a perfect connection between adjacent floor panels can always be guaranteed, even with repeated expansion and shrinkage of the floor surface.
  • This combination of characteristics can be combined or not with the aforementioned characteristic which states that the locking means exert a tension force upon each other.
  • According to a preferred form of embodiment, the floor panels consist of elongated panels and the coupling parts described above are applied at two opposite sides of these panels.
  • According to a particular form of embodiment, coupling parts are provided at the other two sides, too, either of another construction than described above or not.
  • In accordance with the invention, for the core use shall be made of finely-ground wood which is glued, more particularly, watertight glued. Still more particularly, for the core use shall be made of so-called HDF board (High Density Fibreboard) or MDF board (Medium Density Fibreboard).
  • The fact that the invention is applied to floor panels the basic material of which consists of the material described above, offers the advantage that with the processing of this material, very smooth surfaces are obtained whereby very precise couplings can be realized, which, in first instance, is important in the case of a snap-together connection free from play. Also, very special forms of coupling parts can be manufactured in a very simple manner because the aforementioned kinds of material can be processed particularly easy.
  • The surfaces obtained with HDF and MDF also have the advantage that the floor panels mutually can fluently be shifted alongside each other in interlocked condition, even when engaged with a tensioning force.
  • The inventor also found out that the aforementioned materials, in particular HDF and MDF, show ideal features in order to realize a connection, such as mentioned above, as these materials show the right features in respect to elastic deformation in order to, on one hand, realize a snap-together effect, and, on the other hand, receive expansion and shrinkage forces in an elastic manner, whereby it is avoided that the floor panels come unlocked or are damaged in an irreparable manner.
  • The floor covering preferably is form ed by joining the floor panels into each other free of glue. Hereby, the connections are of such nature that the floor panels canbe disassembled without being damaged, such that, for example, when moving, they can be taken along in order to be placed again. It is, however, clear that a glueing between tongue and groove is not excluded.
  • The invention also relates to a method for the manufacturing of the aforementioned floor panels which shows the advantage that the tongues and/or grooves, including the corresponding locking means, can be provided at the floor panels at high production speeds without problems. More particularly, it aims at a method which allows that the rather complicated forms of the tongue and the groove of the aforementioned floor panels can be realized completely by means of milling cutters, the diameter of which can be chosen independently of the form to be realized, such that the use of small milling cutters, for example finger cutters, with diameters smaller than the depth of the tongue or groove can be excluded.
  • To this aim, this method shows the characteristic that the tongue and/or groove is realized by means of a milling process with at least two subsequent milling cycles by means of milling cutters which are positioned in different angles in respect to the related floor panel. During each of the aforementioned milling cycles, preferably substantially the final form of one flank, either of the tongue or of the groove, is realized.
  • For the aforementioned two milling cycles, thus, milling cutters are used which extend outside the groove, respectively the tongue. More particularly the diameters of these milling cutters shall at least be 5 times and even better 20 times larger than the thickness of the floor panels.
  • The use of milling cutters showing the aforementioned diameters has as an advantage that the normal production speeds can be maintained which are also applied during milling of a classical straight tongue and groove. There is also the advantage obtained that the installation of such milling cutters induce only minor or no additional costs because such milling cutters can be placed directly upon a motor shaft and/or the usual machines can be used.
  • Other important features of the invention are represented in the dependent claims.
  • With the intention of better showing the characteristics according to the invention, in the following, as an example without any limitative character, several preferred forms of embodiment are described, with reference to the accompanying drawings. It is to be noted that the coupling parts illustrated in figures 2-4 and 8-11 do not fall within the scope of claim 1.
  • In the drawings:
    • figure 1 represents a floor panel of a floor covering according to the invention;
    • figure 2, on a larger scale, represents a possible cross-section according to line II-II in figure 1;
    • figures 3 and 4 represent how two floor panels with coupling parts according to figure 2 match into each other;
    • figure 5, on a larger scale, represents a cross-section according to line V-V in figure 1;
    • figures 6 and 7 represent how two floor panels with coupling parts according to figure 5 match into each other,
    • figures 8 to 11 represent a number of variants of coupling parts which can be applied in floor panels according to the invention;
    • figure 12 schematically represents how the floor parts can be provided with coupling parts;
    • figure 13 represents a cross-section according to line XIII-XIII in figure 12;
    • figures 14 to 21, on a larger scale and in cross-section, represent the penetration of the milling cutters which are indicated in figure 12 with arrows F14 to F21;
    • figure 22 represents a floor panel according to the invention;
    • figure 23, on a larger scale, represents the coupling of two floor panels of figure 22;
    • figures 24 and 25 represent two manners of coupling floor panels according to figure 22 to each other.
  • The invention relates to a floor covering which is composed of hard floor panels 1, for example, such as shown in figure 1.
  • These floor panels 1 can be of various shape, for example, rectangular or square, or of any other shape.
  • In the most preferred form of embodiment, they shall be manufactured in an elongated form, such as shown in figure 1, for example, with a length of 1 to 2 meters. The thickness, however, can also vary, but is preferably 0,5 to 1,5 cm, and more particularly 0.8 cm.
  • Each floor panel 1 is at least at the edges of two opposite sides provided with coupling parts which allow that two adjacent floor panels 1 can be coupled to each other.
  • Preferably all four edges are provided with coupling parts. In such case, the coupling parts at each pair of opposite edges may be of the same or of different kind
  • Consequently, the coupling parts at two opposite edges show all features of claim 1, whereas the coupling parts at the other two edges need not show these features.
  • As will be clear from the further description, not all embodiments represented in the drawings show all features of appended claim 1. It is dear that in such cases these embodiments relate to coupling parts which can be used in combination with the embodiments corresponding to claim 1, for example in the manner as explained in the preceding paragraph.
  • In figure 1, the opposite sides 2-3 are provided with coupling parts 4-5.
  • The coupling parts 4-5, as represented in the figures 2 to 4, are provided with integrated mechanical locking parts 6 which prevent the drifting apart of two coupled floor panels 1 into a direction D perpendicular to the respective sides 2-3 and parallel to the underside 7 of the coupled floor panels 1; the coupling parts 4-5 and the locking means 6 are realized in one piece with the core 8 of the floor panels 1: the coupling parts 4-5 have such a shape that two subsequent floor panels 1 can be engaged into each other exclusively by turning, and the coupling parts 4-5 preferably provide in an intertocking free from play according to all directions in the plane which is situated perpendicular to the aforementioned edges.
  • In the case of floor panels 1 with an elongated shape, as represented in figure 1, the respective coupling parts 4-5 are situated at the longitudinal sides 2-3.
  • The coupling parts 4-5 can be realized in various forms, although the basic forms thereof will always be formed by a tongue 9 and a groove 10.
  • In figures 2 to 4, the related floor panel 1 is provided with coupling parts 4-5 and locking means 6 which allow to mutually engage two floor panels 1 by means of a turning movement, without the occurance of any snap-together effect.
  • In the represented example, the locking means 6 consist of a first locking element 11 , formed by a protrusion with a bent round shape at the lower side 12 of the tongue 9, and a second locking element 13, formed by a recess with a bent hollow shape in the lower wall 14 of the groove 10.
  • The locking elements 11-13 provide for that two floor panels 1 which are coupled to each other can not perform a lateral movement in the horizontal plane in respect to each other.
  • In order to obtain that two floor panels 1 can be inserted into each other by means of a turning movement, the curvatures preferably are circle-shaped. The bottom side 12 has a curvature with a radius R1, the center of which coincides with the related upper edge 15 of the floor panel 1, whereas the lower wall 14 shows a curvature with a radius R2 which is equal to the radius R1. but whereby its center coincides with the related upper edge 16. Radii R1 and R2 may also be applied which are larger or smaller than the distance to the upper edge 15, 16 respectively, and/or which differ from each other in size.
  • The upper side 17 of the tongue 9 and the upper wall 18 of the groove 10 are preferably flat and preferably are situated in the horizontal plane.
  • The front sides 19 and 20 of the tongue 9 and the groove 10 of two interlocked floor panels 1 preferably do not fit closely against each other, such, that in between an intermediate space 21 is created into which possible dust remainders or such can be pushed away by means of the tongue 9.
  • The tongue 9 and the groove 10 preferably have shapes which are complementary to each other, such that the tongue 9 in the engaged condition of two floor panels 1 precisely sits against the upper wall 18 and the lower wall 14 of the groove 10, whereby a pressure P. executed onto the upper lip 22, is received not only by this lip 22, but by the complete structure, because this pressure can be transmitted through the tongue 9 and the lower lip 23.
  • It is, however, clear that a number of minor deviations to these complementary forms can occur which, anyhow, have no or almost no effect upon the receipt and transmission of pressure forces. For example, a chamfer 24 and a recess 25 can be provided, as represented in figures 2 to 4, as a result of which is obtained that the subsequent floor panels 1 can easily be pushed into each other, such that no possible ridges or such render the good insertion difficult.
  • As represented in the figures 5 to 7, the floor panels 1 according to the invention can also, along the sides 26-27 which are at a right angle to the sides 2-3. be provided with coupling parts 28-29 which have locking means 30, too. The coupling parts 28-29 are also realized in the shape of a tongue 31 and a groove 32. Hereby, the locking means 30 do not have to be of the same nature as the locking means 6.
  • At the sides 26-27 locking means are applied which allow for an engagement and inter-locking by means of a translation movement T only, as represented in figures 6 and 7. To this aim, the locking means 30 consist of a snap-together connection with locking elements 33 and 34 which grip behind each other.
  • As represented in figures 5 to 7, the locking element 33 consists of a protrusion of the lower side 35 of the tongue 31 which can take place in a recess 36 in the lower wall 37 of the groove 32. The locking element 34 is formed by the upward directed part which limits the recess 36.
  • In this case, the locking elements 33-34 have contact planes 38-39 which are parallel to each other and extend in an inclined manner, according to a direction which simplifies the snapping-together. The tangent line L which is determined by the contact planes 38-39, hereby forms an angle A with the underside 7 which is smaller than 90°.
  • The locking elements 33-34 preferably are provided with inclined portions 40 and 41 which, when engaging two floor panels 1, cooperate with each other in such a manner that the locking elements 33-34 can easily be pushed over each other until they grip behind each other by means of a snap-together effect.
  • The thickness W1 of the tongue 31 preferably is equal to the width W of the groove 32, such that the upper lip 42, when exerting a pressure P, is supported by the tongue 31 which, in its turn, then is supported by the lower lip 43.
  • Analogous to the chamfer 24 and recess 25, a recess 44 and a chamfer 45 are provided also at the edges 28-29.
  • Finally it is to be noted that, according to the invention, the lower lip 43, as represented in figures 5 to 7, is longer than the upper lip 42.
  • It is noted that such a snap-together coupling can also be applied at the edges 2-3. Hereby, this can be a snap-together coupling analogous to these of figures 5 to 7, but this can also be a snap-together coupling whereby other forms of coupling parts are applied, for example, such as represented in figures 8 and 9. Contrary to the locking elements 33-34 which consist of rather local protrusions, in the forms of embodiment of figures 8 and 9 use is made of locking elements 46-47 which, in comparison to the total width B of the coupling, extend over a rather large distance.
  • In this case, the locking elements 46-47 are also provided at the lower side 12 of the tongue 9 and the lower wall 14 of the groove 10.
  • According to figure 8, the locking elements 46-47 have contact surfaces 48-49 which are at an angle with the plane of the floor panel 1. Hereby, a coupling is obtained which is interlocked in a particularly fixed manner.
  • As represented in figure 9, the locking elements 46-47 possibly can be realized in such a manner that substantially only a linear contact is obtained, for example, because the contact surfaces directed towards each other are realized with different curvatures.
  • The surfaces, directed towards each other, of the locking elements 46-47 hereby consist of bent surfaces. The tangent line L forms an angle A which is smaller than 90°, and even better is smaller than 70°.
  • Hereby, the locking element 46 preferably has two portions with a different curvature, on one hand, a portion 50 with a strong curvature and, on the other hand, a portion 51 with a weak curvature. The portion 50 with the strong curvature provides for the formation of a firm coupling. The portion 51 with the weak curvature allows that the coupling parts 4-5 can be brought into each other easily. The intermediate space S forms a chamber which offers space for dust and similar which, when engaging two floor panels 1, gets there eventually.
  • In the case of a snap-together connection, for example, a connection, such as represented in figures 7 to 9, preferably always the tongue 9-31 has a shape, thickening towards below, which can cooperate with a widened portion in the groove 10.
  • In figure 10, a variant is represented whereby at least at the height of the upper edges 15-16, a sealing material 52 is provided, as a result of which a watertight sealing can be guaranteed. This sealing material 52 may consist of a strip or covering which is provided previously at the floor panel 1, either at one or both upper edges 15-16.
  • In figure 11, a further variant is represented, whereby the locking means 6 are formed by an upward directed portion 53 at the tongue 9 which, as a result of a turning movement, is brought behind a downward-directed portion 54 at the upper wall 18. More particularly, this is obtained by realizing the upper side 17 and the upper wall 18 with a curvature R3, the center of which is situated at the edges 15-16, and realizing the lower side 12 and the lower wall 14 with a radius R4, the center of which is also situated at the upper edges 15 and 16, respectively. These radii R3-R4 can be chosen otherwise, too.
  • In general, the difference between, on one hand, the radius R1, R3 respectively, and, on the other hand, the radius R2, R4 respectively, preferably should not be larger than 2 mm.
  • It is also preferred that the center of these radii is situated inside the circle C1, C2 respectively, which extends with a radius R5 of 3 mm around the upper edge 15, 16 respectively, such as, for example, indicated In figure 2.
  • Finally is noted that, according to the invention, the lower lip 23-43, as represented in figures 5 to 7, is realized longer than the upper lip 22-42. This has as an advantage that the coupling parts 4-5-28-29 can be realized in an easier manner by means of a milling cutter or such. Furthermore, this simplifies the engagement of two floor panels 1, because each subsequent floor panel 1 during installation can be placed upon the protruding lower lip 23-43, as a result of which the tongue 9-31 and the groove 10-32 automatically are positioned in front of each other.
  • Edges whereby the lower lip 23 is equal to or shorter than the upper lip 22, in their turn, offer the advantage that no protruding lip 23 remains at the extreme edge of the floor which might cause problems in the finishing.
  • In order to allow for a smooth assembly, in order to guarantee the necessary stability and firmness and in order to limit the quantity of material to be cut away, the difference E between the upper lip 22-42 and the lower lip 23-43, measured in the plane of the floor panel and perpendicular to the longitudinal direction of the groove 10, is kept smaller than one time the total thickness F of the floor panel 1. For stability's sake, normally this total thickness F shall never be less than 5 mm.
  • The small dimension of the difference E offers the advantage that the lower lip must not be strengthened by a reinforcement strip or the like.
  • According to a particular form of embodiment, the central line M1 through the tongue 9 and the groove 10 is situated lower than the center M2 of the floor panel 1, such, that the upper lip 22-42 is thicker than the lower lip 23-43. In first instance, this is essential in this kind of connections, because then it is the lower lip 23-43 which bends, such that the upper side of the floor panel 1 is kept free of possible deformations.
  • The invention shows its usefulness, in first instance, preferably with laminated flooring, due to the reasons explained in the introduction.
  • As represented in the examples of the figures 2 to 11, such laminated flooring preferably consists of a core 8 made of MDF board, HDF board or similar, whereby at least at the upper side of this core 8 one or more layers of material are provided.
  • More particularly, it is preferred that the laminated flooring is provided with a decorative layer 55 and a protective top layer 56. The decorative layer 55 is a layer, impregnated with resin, for example, made of paper, which can be imprinted with a variety of patterns, such as a wood pattern, a pattern in the form of stone, cork, or similar or even with a fancy pattern. The protective top layer 56 preferably also consists of a layer saturated with resin, for example, melamine resin, made of a transparent material.
  • It is clear that still other layers can be applied, such as an intermediate layer 57 upon which the decorative layer 55 is provided
  • Preferably, also a backing layer 58 shaft be applied at the underside 7. forming a counterbalancing element for the top layers and, thus, guaranteeing the stability of the form of the floor panel 1. This backing layer 58 may consist of a material, for example paper, impregnated with a resin, for example, a melamine resin.
  • As represented schematically in figure 12, the tongue 9 and the groove 10, and preferably also the tongue 31 and the groove 32 are applied by means of a milling process. In the case that a profile has to be applied on all four sides, the floor panels 1 preferably shall be displaced by means of two perpendicular movements V1 and V2, whereby during the first movement profiles at two opposite edges are provided, in this case the longitudinal edges, by means of milling devices 59-60, whereas during the second movement profiles are provided at the other edges, in this case the small edges, by means of milling devices 61-62. During these processing, the floor panels 1 preferably are put with their decorative layer directed downward.
  • According to an important characteristic of the invention, each respective tongue 9-31 and groove 10-32 are realized by means of a milling process with at least two subsequent milling cycles by means of milling cutters which are positioned at different angles in reference to the related floor panel 1.
  • This is illustrated in figures 13, 14 and 15, wherein it is represented how a groove 10 is realized by means of two milling cycles by means of two milling cutters 63 and 64. Figures 16 and 17 represent how the tongue 9 is realized by means of milling cutters 65 and 66.
  • The figures 18-19 and 20-21 represent similar views showing how the groove 32 and the tongue 31 are realized by means of milling cutters 67-68 and 69-70, positioned at an angle.
  • During each of the aforementioned milling cycles, each time substantially the final shape of one flank is realized. For example, the milling cutter 63 of figure 14 determines the final shape of the lower flank 71 of the groove 10, whereas the milling cutter 64 determines the final shape of the upper flank 72.
  • As mentioned in the introduction, preferably mining cutters 63 to 72 shall be applied, having diameters G which are at least 5 times, and even better at least 20 times larger than the thickness F of the floor panels 1.
  • Apart of the mentioned milling cutters, preferably still other milling cutters are applied, for example, in order to remove a part of the material to be removed already during a first premachining cycle.
  • In the figures 22 to 25, a particularly preferred form of embodiment of a floor panel 1 according to the invention is represented. Hereby, the parts which are taken overfrom the aforegoing forms of embodiment are indicated with corresponding references.
  • An important characteristic herein consists in that the coupling parts 4-5 are provided with locking means 6 which, in engaged condition, exert a tension force upon each other, as a result of which the engaged floor portions 1 are forced towards each other. As represented, this is realized preferably by providing the coupling parts with an elastically bendable portion, in this case the lip 43, which, in engaged condition, is at least partially bent and in this way creates a tension force which provides for that the engaged floor panels 1 are forced towards each other. The hereby resulting bending V. as well as the tension force K resulting herefrom, are indicated in the enlargement of figure 23.
  • In order to obtain that the tension force K results in pressing together the engaged floor panels 1, the bendable portion, in this case the lip 43, preferably is provided, as represented, with an inwardly inclined contact surface 73 which preferably can cooperate with a corresponding contact surface 74. These contact surfaces 73-74 are similar to the aforementioned contact surfaces 39-38 and also similar to the inclined portions of the lower lip of figures 5 to 7.
  • In the figures 2 and 5, the portions form complementary matching shapes; it is, however, dear that, by a modification, also a tension effect similar as in figure 23 can be realized.
  • Due to, on one hand, the contact under the angle A, and, on the other hand, the fact that a tension force K is created, a force component K1 is effected, as a result of which the floor panels 1 are drawn against each other.
  • Preferably, the angle A of the contact surfaces 73-74 in respect to the horizontal plane is situated between 30 and 70 degrees. In first instance in the case that use is made of the embodiment whereby a tension force K is realized, an angle A of 30 to 70 degrees is ideal in order, on one hand, to effect an optimum pressing-together of the floor panels 1 and, on the other hand, to obtain that the floor panels 1 can easily be engaged, respectively disassembled.
  • Although the pressing force K1 preferably is delivered by the aforementioned lip 43, the invention does not exclude other forms of embodiment whereby this force is delivered by other bendable portions.
  • It is noted than the bending V is relatively small, for example, several hundredths up to several tenths of a millimeter, and does not have an influence upon the placement of the floor covering. Furthermore is noted that such floor covering generally is placed upon an underlayer which is elastically compressible, as a result of which the bending V of the lip 43 exclusively results in the fact that the underlayer locally is compressed somewhat more.
  • Due to the fact that the lip 43 is bent apart and that it remains somewhat bent apart in engaged position, also the advantage is effected that, when exerting a pressure upon the floor covering, for example, when placing an object thereupon, the pressing-togetherforce is enhanced and, thus, the development of gaps is counteracted even more.
  • It is noted that the inventor has found that, contrary to all expectations, an ideal tension force can be realized by manufacturing the coupling parts 4-5, including the locking elements 33-34. and the complete core 8, of HDF board or MDF board, although these materials only allow a minor elastic deformation.
  • HDF and MDF also offer the advantage that smooth surfaces are obtained, as a result of which the locking elements can be moved easily over each other.
  • A further particular characteristic of the embodiment of figures 22 to 25 consists in that the floor panels 1 can be engaged by means of a turning movement, as represented in figure 24, as well as by means of shifting them towards each other, as represented in figure 25, preferably in such a manner that, during the engagement by means of the turning movement, a maximum bending Vm results in the coupling parts, more particularly in the lip 43, which bending Vm is less pronounced, if not non-existent, as in the figures 2 to 4, in comparison to the bending Vm which results when the floor panels 1 are engaged by means of shifting them towards each other.
  • The advantage of this consists in that the floor panels 1 can be engaged easily by means of a turning movement, in otherwords by means of the angling down or pivoting thereof, without necessitating a tool therefore, whereas it still remains possible to engage the floor panels also by means of shifting them. This latter is useful, in first instance, when the last panel has to be placed partially under a door frame or similar. In this case, the floor panel 1 can be pushed under the door frame with the side which does not have to be engaged and subsequently, possibly by means of tools, can be snapped into the adjacent floor panel 1.
  • It is noted that the shapes of the coupling parts 4-5 shown in figures 22 to 25 can also be used for the coupling parts 28-29 of the short sides.
  • According to the invention, in the case that the four sides 2-3-26-27 are provided with coupling parts 4-5-28-29, these coupling parts can be realized in such a manner that in one direction a firmer engagement than in the other direction is effected. In the case of elongated floor panels 1, for example, such as represented in figure 1, the locking at the small sides 26-27 preferably shall be more pronounced than at the longitudinal sides 2-3. The length of the coupling at the small sides, namely, is smaller and, in principle, less firm. This is compensated by providing in a more pronounced locking.
  • This difference in engagement can be obtained by realizing the contact surfaces 73-74 under different angles.
  • Preferably, the aforementioned protrusion, more particularly the locking element 33, is bordered by at least two portions 75-76, respectively a portion 75 with a strong inclination which provides for the locking, and a portion 76 with a weaker inclination which renders the engagement of the coupling parts easier. In the embodiment of figures 22 to 25, these portions 75-76 are formed by straight planes, but, as already described in reference to figure 9, use can also be made of curved portions 50-51. In figure 5, these are the contact surface 38 and the inclined portion 40.
  • In the preferred form the floor panels 1 comprise coupling parts 4-5 and/or 28-29 showing one of the following or the combination of two or more of the following features:
    • a curvature 77 at the lower side of the tongue 9 and/ or a curvature 78 at the lip 43 which form a guidance when turning two floor panels 1 into each other, with the advantage that the floor panels 1 can be engaged into each other easily during installing;
    • roundings 79-80 at the edges of the locking elements 33-34, with the advantages that the locking elements can easily shift over each other during the engagement, respectively disassembly of the floor panels 1 and that the locking elements are not damaged, for example, crumble away at their edges, even if the floor panels are engaged, respectively disassembled, repeatedly;
    • dust chambers 81, or spaces 21 as in figure 4. between all sides, directed laterally towards each other, of the engaged floor panels 1. with the advantage that inclusions which get between the floor panels 1 during the engagement do not exert a disadvantageous influence upon the good engagement;
    • a shaping of the tongue 9 which is such, for example, by the presence of a chamfer 82, that the upper side of the tongue 9 already with the first contact becomes situated under the lower side of the upper lip 42 when the floor panels 1 are pushed towards each other at the same level, as indicated in figure 25, with the advantage that the front extremity of the tongue 9 does not press against the front side of the upper lip 42 when the floor panels are pushed towards each other at the same level;
    • a ramp surface 83, hereinbefore also called inclined portion 41, formed at the free extremity of the lower lip 43, with the advantage that the locking elements 33-34 shift smoothly over each other and that the lower lip 43 is bent uniformly:
    • in the engagement direction only one important contact point which is formed by a section 84 at the location of the top side of the floor panels 1, with the advantage that the aforementioned tension force is optimally transferred to the upper side of the floor panels 1 and that the development of openings between the floor panels 1 is counteracted;
    • contact surfaces 85-86. more particularly abutment surfaces, formed by the upper side of the tongue 9 and the upper side of the groove 10 which, over the largest portion of their length, run parallel to the plane which is defined by the floor panels 1. as well as contact surfaces cooperating with each other, formed by curvatures 77-78, with the advantage that no mutual displacement in height between two engaged floor panels 1 is possible, even if the insertion depth of the tongue 9 into the groove 10 should vary due towhich causes whatsoever, in other words, that no height differences may occur between the adjacent floor panels.
  • In the form of embodiment of figures 22 to 25, all these characteristics are combined; it is, however, clear that, as becomes evident from figures 2 to 11. these features can also be present separately or in a limited combination.
  • As becomes evident from figures 5 to 7 and 22 to 25, an important characteristic of the embodiment of the invention consists in that the locking means 6, in otherwords, the portion providing for the snap-together and engagement effect, are situated in that portion of the lower lip 23-43 which extends beyond the upper lip 22-42, more particularly, that the lowermost point 87 of the locking part 33 is situated under the top layer of the floor panel 1. For clarity's sake, this top layer is indicated in the figures 22 to 25 only as a single layer.
  • It is noted that the combination of features, that the lower lip 23-43 extends further than the upper lip 22-42, that the locking means 6 are formed at least by means of a portion which inwardly slopes downward, and that this portion, at least partially, is located in the portion of the lower lip 23-43 which extends beyond the upper lip 22-42, is particularly advantageous, among others, in comparison with the coup tings for floor panels described in the documents WO 94/01 628. WO 94/26999. WO 96/27719 and WO 96/27721. The sloping portion offers the advantage that the floor panels 1 can be disassembled again. The fact that this sloping portion is situated in the further extending portion of the lower lip 23-43 additionally to this offers the advantage that no deformations can occur during coupling which manifest themselves up to the top layer.
  • According to a preferred characteristic of the invention, the aforementioned portion, i.e. the contact surface 39 or 73, preferably extends in such a manner that the distance up to the upper edge 16 diminishes from below in upward direction, in other words, such that, as represented in figure 22, the distance X2 is smaller than the distance X1. This is also the case in figure 7.
  • Still preferably, this portion only starts at a clear distance E1 from the upper lip 42.
  • It is obvious that the coupling parts 22 to 25 can also be realized by means of said milling process.
  • According to a particular characteristic the floor panels 1 are treated at their sides 2-3 and/or 26-27 with a surface densifying agent, more particularly a surface hardening agent, which preferably is chosen from the following series of products: impregnation agents, pore-seating agents, lacquers, resins, oils, paraffines and similar.
  • In figure 22, such impregnation 88 is represented schematically. This treatment can be performed over the complete surface of the sides 2-3 and/or 26-27 or only over well-defined portions hereof, for example, exclusively the surfaces of the tongue 9 and the groove 10.
  • The treatment with a surface densifying agent offers, in combination with the snap-together effect, the advantage that in various aspects better coupling features are obtained. As a result of this, the coupling parts 4-5 and/or 28-29 better keep their shape and strength, even it the floor panels 1 are engaged and disassembled repeatedly. Since for the core 8 use is made of HDF, MDF or similiar, by means of this treatment such a better quality of surface condition is obtained, that no abrasion of material occurs during engaging, respectively during disassembling.
  • This treatment also offers the advantage that, at least in the case of a surface hardening, the aforementioned elastic tensioning effect is enhanced.
  • The present invention is in no way limited to the forms of embodiment described by way of example and represented in the figures, however, such floor covering and the pertaining floor panels 1 can be realized in various forms and dimensions without leaving the scope of the invention as defined by claim 1.
  • Furthermore, all embodiments of coupling elements described before can be applied at the longer sides as well as at the shorter sides, provided that the coupling elements on at least one pair of sides are in accordance with claim 1.

Claims (33)

  1. Floor covering consisting of hard floor panels comprising a wood-based core of finely ground wood which is glued, chipboard with fine chips, MDF board or HDF Board, which panels are intended to be laid to provide an upwardly facing, flat surface lying in a first horizontal plane and a downwardly facing, substantially flat surface lying in a second horizontal plane,
    said hard floor panels being provided, at least at the edge of two opposite sides (2-3, 26-27) with coupling parts (4-5, 28-29) formed in one-piece with said core and cooperating with each other, substantially in the form of a tongue (9-31) and a groove (10-32),
    said groove being at least delimited by an upper lip (22-42) terminating at a vertical plane and lower lip (23-43), and
    said tongue having a tongue portion extending from the tongue tip inwardly up to said vertical plane when said panels are joined, wherein:
    the lower lip (23-43) is elastically bendable and extends beyond the upper lip (22-42) wherein the distance (E) by which the lower lip extends beyond the upper lip is smaller than one time the total thickness (F) of the floor panel (1); the coupling parts are provided with integrated mechanical locking means (6) made in one piece with said core which prevent the drifting apart of two coupled floor panels in a direction perpendicular to the related edge and parallel to the underside of the coupled floor panels;
    said integrated mechanical locking means comprise on the one hand a protrusion (33) located on the lower surface (35) of said tongue,
    said protrusion extending at least partially beyond said vertical plane inwardly and said protrusion having a contact surface (38, 74), and on the other hand a recess (36) in the lower lip for accommodating said protrusion,
    said recess having a contact surface (39, 73) cooperating with said contact surface of said protrusion such that a tangent line (L) which is defined by said contact surfaces when contacting each other is inclined with respect to said horizontal planes;
    said contact surface (39, 73) of the lower lip is located at least partially in the portion of the lower lip (23-43) extending beyond the upper lip; said protrusion (33), recess (36) and elastically bendable lower lip (23-43) are arranged to permit joining of said panels by shifting them laterally in a planar fashion towards each other, and
    said coupling parts (4-5, 28-29) provide for an interlocking, free from play, according to all directions in the plane which is situated perpendicular to the panel edges.
  2. Floor covering according to claim 1, characterized in that at least the contact surface (39-73) at the lower lip (23-43) is inwardly inclined.
  3. Floor covering according to either of the preceding claims, characterized in that both contact surfaces (38-39, 73-74) are inclined.
  4. Floor covering according to any of the preceding claims, characterized in that the thickness of the lower lip (23-43) increases from the deepest point of the recess towards the innermost point of the groove (10).
  5. Floor covering according to any of the preceding claims, characterized in that the tongue (9-31) and groove (10-32) have a shape such that in coupled condition of two floor panels (1) there exists a chamber (81) between those sides of the protrusion and the recess (36) that are located opposite to the sides at which the contact surfaces (39-73) are formed.
  6. Floor covering according to any of the preceding claims, characterized in that both contact surfaces (12-14. 38-39. 74-73) are indined and have corresponding inclinations.
  7. Floor covering according to any of the preceding claims, characterized in that the coupling parts (4-5, 28-29) have such a shape that two subsequent floor panels (1) can be engaged into each other by shifting them laterally together as well as by turning.
  8. Floor covering according to any of the preceding claims, characterized in that the total thickness (F) of each floor panel (1) is larger than or equal to 5 mm.
  9. Floor covering according to any of the preceding claims, characterized in that the floor panels (1) consist of elongated panels and that, at least at their longitudinal sides (2-3), they are provided with the aforementioned coupling parts (4-5).
  10. Floor covering according to any of the preceding claims, characterized in that the floor panels (1) are rectangular or square and that, on all four sides (2-3-26-27), more particularly two by two, they are provided with the aforementioned coupling parts (4-5-28-29).
  11. Floor covering according to any of the preceding claims, characterized in that the lower surface of the aforementioned protrusion is bordered by at least two portions (38-40, 75-76), respectively a portion (38-75) with a strong Inclination providing for the locking effect, and a portion (40-76) with a weaker inclination which renders the engagement of the coupling parts (4-5) easier.
  12. Floor covering according to any of the preceding claims, characterized in that the lowermost point (87) of engagement of the locking elements is located underneath the top layer of the floor panel (1) which carries the related tongue (9).
  13. Floor covering according to any of the preceding claims, characterized in that the shaping of the tongue (9-31) and/or the lower lip (43) are such that the floor panels (1) can be coupled by laterally shifting them towards each other, starting from a mutual position in which the floor panels (1) at the edges to be coupled, are completely separated from each other.
  14. Floor covering according to any of the preceding claims, characterized in that the upper side of the tongue tip already at the first contact with the upper lip (42) is located underneath the upper lip (42) when the floor panels (1) are shifted towards each other.
  15. Floor covering according to any of the preceding claims, characterized in that the lower lip (43) at the free extremity thereof is provided with a ramp surface (41-83), said ramp surface (41-83) allowing that a first floor panel (1), when shifting it over the floor to a second floor panel (1), is guided with its protrusion over said ramp surface.
  16. Floor covering according to any of the preceding claims, characterized in that in the engagement direction, apart from said contact surfaces (39-73) there exists only one substantial contact point between two coupled floor panels (1), which is formed by a section (84) at the location of the top side of the floor panels (1).
  17. Floor covering according to any of the preceding claims, characterized in that said floor panels (1) are provided with contact surfaces (85-86), more particularly abutment surfaces, formed by the upper side of the tongue (9-31) and the upper side of the groove (10) which, over the largest portion of their length, run parallel to the plane which is defined by the floor panels (1).
  18. Floor covering according to any of the preceding claims, characterized in that the lower lip (23-43) has a thickness which is smaller than the thickness of the upper lip.
  19. Floor covering according to any of the preceding claims, characterized in that the underside of the upper lip (22-42) is provided with a chamfer (24-45).
  20. Floor covering according to any of the preceding claims, characterized in that the upper side of the upper lip (22-42) is in the same plane as the upper surface of the panel (1).
  21. Floor covering according to any of the preceding claims, characterized in that the portion of the lower lip (23-43) located beyond the upper lip (22-42) is located completely below the level defined by the lower side of the upper lip (22-42).
  22. Floor covering according to claim 21, characterized in that said portion of the lower lip is located completely below the central line M2 of the panel.
  23. Floor covering according to any of the preceding claims, characterized in that the panels (1) have short sides and longer sides and in that the locking means (6) comprise contact surfaces which at the short sides have a stronger inclination than at the longer sides.
  24. Floor covering according to any of the preceding claims, characterized in that the tongue (9-31) and the groove (10-32) have a profile which can be produced by milling, preferably by means of milling cutters having a diameter which is at least 20 times larger than the thickness (F) of the floor panels (1).
  25. Floor covering according to claim 24, characterized in that the edges of the panels have a profile which can be milled in two milling actions.
  26. Floor covering according to any of the preceding claims, characterized in that the lower lip has an indined portion (39-73) which extends in such a manner that the distance (X1-X2) up to the upper edge (16) of the floor panel (1) diminishes from below in upward direction.
  27. Floor covering according to any of the preceding claims, characterized in that the floor panels (1) are realized as laminated flooring, whereby on the core (8) one or more layers, among which a decorative layer (55) forming said decorative surface, are provided and whereby a backing layer (58) is provided at the underside (7).
  28. Floor covering according to any of the preceding claims, characterized in that the floor panels (1) are connected free of glue, such that they can be disassembled and be re-used.
  29. Floor panel for realizing a floor covering according to any of the claims 1 to 28.
  30. Method for manufacturing floor panels as described in any of the preceding claims, characterized in that the tongue (9-31) and/or groove (10-32) is realized by means of a milling process with at least two subsequent milling cycles by means of milling cutters (63-64-65-66-67-68-69-70) which are positioned in different angles in respect to the related floor panel (1).
  31. Method according to claim 30, characterized in that during each of the aforementioned milling cycles each time substantially the final shape of one flank (71-72), either of the tongue or of the groove, is realized.
  32. Method according to claim 30 or 31, characterized in that for the aforementioned two milling cydes milling cutters (63-64-65-66-67-68-69-70) are applied which extend outside the groove (10-32), respectively the tongue (9-31), and more particularly show diameters (G) which are at least 5 times larger than the thickness (F) of the floor panels (1), and preferably even at least 20 times larger than the thickness (F) of the floor panels (1).
  33. Method according to any of the claims 30 to 32, characterized in that at all four sides of the floor panel (1) a profile is provided and that the floor panels (1) are displaced according to two perpendicular movements (V1-V2), whereby during one of the movements profiles at two opposite edges are provided, whereas during the other movement profiles are provided at the small edges.
EP97928169A 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels Expired - Lifetime EP0843763B2 (en)

Priority Applications (23)

Application Number Priority Date Filing Date Title
EP08075888A EP2031149B1 (en) 1996-06-11 1997-06-07 Laminate floor panel
EP08020830.9A EP2031148B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP05077327A EP1614829B1 (en) 1996-06-11 1997-06-07 Method of manufacturing hard floor panels
EP05076551A EP1589161B1 (en) 1996-06-11 1997-06-07 Floor covering consisting of hard floor panels
EP05077262A EP1612346B1 (en) 1996-06-11 1997-06-07 Floor covering consisting of hard panels
EP10010508A EP2280133A3 (en) 1996-06-11 1997-06-07 Hard floor panel and method for manufacturing the same
EP00201514A EP1026341B1 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP05077348.0A EP1614828B1 (en) 1996-06-11 1997-06-07 Hard floor panel and floor covering
EP08020631.1A EP2077358B1 (en) 1996-06-11 1997-06-07 Hard floor panel with integrated mechanical locking means
EP10011062A EP2275623A3 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP10010484A EP2280132A3 (en) 1996-06-11 1997-06-07 Floor panel
EP08021267A EP2031147A3 (en) 1996-06-11 1997-06-07 Hard floor panels, floor coverings consisting of hard floor panels, methods of assembling hard floor panels and method for manufacturing such floor panels
EP05075560A EP1541778B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP10010510A EP2280135A3 (en) 1996-06-11 1997-06-07 Method for manufacturing a hard floor panel
EP10010811A EP2275622A3 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP09010320A EP2116668A1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP03076384A EP1338721B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP10010483A EP2280131A3 (en) 1996-06-11 1997-06-07 Floor panel
EP00201515A EP1024234B2 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels
EP02076363A EP1223267B2 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels
EP10010509A EP2280134A3 (en) 1996-06-11 1997-06-07 A floor panel and a method for manufacturing the same
EP05075635A EP1541779B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP07024053.6A EP1898026B1 (en) 1996-06-11 1997-06-07 Hard floor panel with integrated mechanical locking means

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
BE9600527A BE1010339A3 (en) 1996-06-11 1996-06-11 Floor covering comprising hard floor panels and method for producing them
BE9600527 1996-06-11
BE9700344A BE1010487A6 (en) 1996-06-11 1997-04-15 FLOOR COATING CONSISTING OF HARD FLOOR PANELS AND METHOD FOR MANUFACTURING SUCH FLOOR PANELS.
BE9700344 1997-04-15
PCT/EP1997/003006 WO1997047834A1 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels

Related Child Applications (2)

Application Number Title Priority Date Filing Date
EP00201514A Division EP1026341B1 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP00201515A Division EP1024234B2 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels

Publications (3)

Publication Number Publication Date
EP0843763A1 EP0843763A1 (en) 1998-05-27
EP0843763B1 EP0843763B1 (en) 2000-10-04
EP0843763B2 true EP0843763B2 (en) 2006-11-29

Family

ID=25663046

Family Applications (24)

Application Number Title Priority Date Filing Date
EP08020631.1A Expired - Lifetime EP2077358B1 (en) 1996-06-11 1997-06-07 Hard floor panel with integrated mechanical locking means
EP05075635A Expired - Lifetime EP1541779B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP10011062A Withdrawn EP2275623A3 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP10010484A Withdrawn EP2280132A3 (en) 1996-06-11 1997-06-07 Floor panel
EP08020830.9A Expired - Lifetime EP2031148B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP97928169A Expired - Lifetime EP0843763B2 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP05077348.0A Expired - Lifetime EP1614828B1 (en) 1996-06-11 1997-06-07 Hard floor panel and floor covering
EP09010320A Withdrawn EP2116668A1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP10010508A Withdrawn EP2280133A3 (en) 1996-06-11 1997-06-07 Hard floor panel and method for manufacturing the same
EP05077262A Expired - Lifetime EP1612346B1 (en) 1996-06-11 1997-06-07 Floor covering consisting of hard panels
EP00201515A Expired - Lifetime EP1024234B2 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels
EP05076551A Expired - Lifetime EP1589161B1 (en) 1996-06-11 1997-06-07 Floor covering consisting of hard floor panels
EP02076363A Expired - Lifetime EP1223267B2 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels
EP00201514A Expired - Lifetime EP1026341B1 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP05077327A Expired - Lifetime EP1614829B1 (en) 1996-06-11 1997-06-07 Method of manufacturing hard floor panels
EP03076384A Expired - Lifetime EP1338721B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP05075560A Expired - Lifetime EP1541778B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP08075888A Expired - Lifetime EP2031149B1 (en) 1996-06-11 1997-06-07 Laminate floor panel
EP10010811A Withdrawn EP2275622A3 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP10010510A Withdrawn EP2280135A3 (en) 1996-06-11 1997-06-07 Method for manufacturing a hard floor panel
EP10010483A Withdrawn EP2280131A3 (en) 1996-06-11 1997-06-07 Floor panel
EP08021267A Withdrawn EP2031147A3 (en) 1996-06-11 1997-06-07 Hard floor panels, floor coverings consisting of hard floor panels, methods of assembling hard floor panels and method for manufacturing such floor panels
EP10010509A Withdrawn EP2280134A3 (en) 1996-06-11 1997-06-07 A floor panel and a method for manufacturing the same
EP07024053.6A Expired - Lifetime EP1898026B1 (en) 1996-06-11 1997-06-07 Hard floor panel with integrated mechanical locking means

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EP08020631.1A Expired - Lifetime EP2077358B1 (en) 1996-06-11 1997-06-07 Hard floor panel with integrated mechanical locking means
EP05075635A Expired - Lifetime EP1541779B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP10011062A Withdrawn EP2275623A3 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP10010484A Withdrawn EP2280132A3 (en) 1996-06-11 1997-06-07 Floor panel
EP08020830.9A Expired - Lifetime EP2031148B1 (en) 1996-06-11 1997-06-07 Hard floor panel

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EP05077348.0A Expired - Lifetime EP1614828B1 (en) 1996-06-11 1997-06-07 Hard floor panel and floor covering
EP09010320A Withdrawn EP2116668A1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP10010508A Withdrawn EP2280133A3 (en) 1996-06-11 1997-06-07 Hard floor panel and method for manufacturing the same
EP05077262A Expired - Lifetime EP1612346B1 (en) 1996-06-11 1997-06-07 Floor covering consisting of hard panels
EP00201515A Expired - Lifetime EP1024234B2 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels
EP05076551A Expired - Lifetime EP1589161B1 (en) 1996-06-11 1997-06-07 Floor covering consisting of hard floor panels
EP02076363A Expired - Lifetime EP1223267B2 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels
EP00201514A Expired - Lifetime EP1026341B1 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP05077327A Expired - Lifetime EP1614829B1 (en) 1996-06-11 1997-06-07 Method of manufacturing hard floor panels
EP03076384A Expired - Lifetime EP1338721B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP05075560A Expired - Lifetime EP1541778B1 (en) 1996-06-11 1997-06-07 Hard floor panel
EP08075888A Expired - Lifetime EP2031149B1 (en) 1996-06-11 1997-06-07 Laminate floor panel
EP10010811A Withdrawn EP2275622A3 (en) 1996-06-11 1997-06-07 Floor covering, consisting of hard floor panels and method for manufacturing such floor panels
EP10010510A Withdrawn EP2280135A3 (en) 1996-06-11 1997-06-07 Method for manufacturing a hard floor panel
EP10010483A Withdrawn EP2280131A3 (en) 1996-06-11 1997-06-07 Floor panel
EP08021267A Withdrawn EP2031147A3 (en) 1996-06-11 1997-06-07 Hard floor panels, floor coverings consisting of hard floor panels, methods of assembling hard floor panels and method for manufacturing such floor panels
EP10010509A Withdrawn EP2280134A3 (en) 1996-06-11 1997-06-07 A floor panel and a method for manufacturing the same
EP07024053.6A Expired - Lifetime EP1898026B1 (en) 1996-06-11 1997-06-07 Hard floor panel with integrated mechanical locking means

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